Composite Vault Liner Panel With Mechanical Bonding Fill

Solution Overview

Problem

Existing concrete structures in public works, such as manholes and vaults, suffer from structural integrity issues due to corrosion and ground shifting, leading to costly and time-consuming replacement or repair, with metallic panel braces increasing material and installation costs.

Innovation Solution

A composite panel system with a fluid-impermeable layer, embedded mechanical bonding agent, and fiber-reinforced spacer boards that attach to the base wall, allowing for a quick, easy, and cost-effective installation, using lightweight materials to form a mechanical bond with a hardening fill without specialized bracing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metallic panel braces are used to attach the rigid panel to the base wall, then structural support and rigidity are improved, but material costs and installation time increase

Engineering Contradiction:

Improvestructural supportVSAvoidinstallation time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent removes the metallic panel braces from the system entirely. Instead, the rigid panel itself is made composite with an integrated foam core that provides structural rigidity, and the adhesive bonding system provides the necessary attachment strength without requiring separate metallic bracing components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses a composite rigid panel structure consisting of an outer shell with an integrated foam core material. This composite construction provides the necessary structural support and rigidity that previously required separate metallic braces, while reducing material costs and simplifying installation.

Inventive Principle:

Principle #40Composite materials

2Strength

If metallic panel braces are used to attach the rigid panel to the base wall, then structural support is improved, but material costs increase

Engineering Contradiction:

Improvestructural supportVSAvoidmaterial costs

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent removes the metallic panel braces from the system entirely. Instead, the rigid panel itself is made composite with an integrated foam core that provides structural rigidity, and the adhesive bonding system provides the necessary attachment strength without requiring separate metallic bracing components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses a composite rigid panel structure consisting of an outer shell with an integrated foam core material. This composite construction provides the necessary structural support and rigidity that previously required separate metallic braces, while reducing material costs and simplifying installation.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If a composite panel with embedded mechanical bonding agent is used, then ease of installation is improved, but the complexity of the panel structure increases

Engineering Contradiction:

Improveease of installationVSAvoidpanel structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent combines the mechanical bonding agent directly into the adhesive layer that is already part of the panel attachment system. This integration means the bonding functionality is built into the existing structure rather than adding separate components, thereby improving ease of installation without significantly increasing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The composite panel system provides structural reinforcement and corrosion resistance, reducing material costs and installation time while ensuring a dependable repair with minimal materials, forming a strong bond with the base wall.

Implementation Method 1

The second side has a resin with an embedded mechanical bonding agent... to be mechanically bonded to the second side of the first composite panel when hardened and mechanically bonded to the first base wall

Methodology Applied

Scientific EffectMechanical bonding:

Data Source

PatentUS12546130B2Composite panel system and a method of utilizing the composite panel

Publication Date: 2026.02.10 GENEVA PIPE & PRECAST CO

AI summary

Disclosed is a composite panel, and a system and method utilizing the composite panel. The composite panel is a fiber-reinforced plastic panel, wherein a first side of the composite panel fluid is impermeable and non-porous and faces the interior of an existing concrete vault. The second side of the composite panel has a mechanical bonding agent embedded in a polyester resin. When a hardening fill is poured between the second side of the composite panel and the wall of the existing vault, a mechanical bond is formed between the hardening fill and the embedded mechanical bonding agent. A plurality of spacer boards are affixed to the second side and extend toward the wall of the existing vault. A plurality of conduits are formed through the composite panel and the spacer boards, and a plurality of fasteners extend through respective conduits to attach to the wall of the existing vault.